A design method and system for 3D decorative cups incorporating planar lenticular patterns

Abstract

This invention discloses a 3D decorative cup design method and system combining planar grating patterns, relating to the field of decorative cup manufacturing technology. The method includes: acquiring a geometric model and an initial planar grating pattern for the 3D decorative cup; performing feature analysis on the geometric model to obtain geometric feature information of the cup surface; dividing the cup surface into regions based on the geometric feature information to obtain multiple local regions; establishing a set of deformation compensation strategies; selecting a target compensation strategy from the set of deformation compensation strategies based on the regional geometric features of the local regions and injection molding process parameters; geometrically correcting the local patterns corresponding to the local regions in the initial planar grating pattern to obtain corrected patterns; and integrating multiple corrected patterns to obtain a pre-compensated planar grating pattern, which is used for grating film fabrication. This invention can combine the features of each local region for grating pattern pre-compensation to achieve decorative cup design, improving pre-compensation accuracy.

Description

Technical Field

[0001] This invention relates to the field of decorative cup manufacturing technology, and in particular to a 3D decorative cup design method and system that incorporates planar grating patterns. Background Technology

[0002] In the manufacturing process of planar grating patterns, after a flat grating film is fed into a mold cavity, molten plastic is injected into the cavity, pressing the grating film against the mold surface. The film naturally stretches and deforms. For grating patterns that rely on precise microstructure, any stretching or compression directly alters the spacing and angle of the grating lines, leading to distortion in the final 3D visual effect. To ensure that a planar grating pattern maintains a clear and consistent 3D effect when applied to a complexly shaped cup, technicians need to perform precise deformation processing on the pattern beforehand—a pre-compensation design. Existing methods are typically based on mathematical calculations of simple geometric shapes. However, for complex surfaces with non-uniform curvature, their predictive ability significantly decreases, failing to accurately capture local stretching differences in different curvature regions of the film. This results in low pre-compensation accuracy, failing to meet the requirements of high-precision pattern application.

[0003] In summary, the technical problems existing in the relevant technologies need to be improved. Summary of the Invention

[0004] The main objective of this invention is to propose a 3D decorative cup design method and system that combines planar grating patterns. This method can perform grating pattern pre-compensation based on the characteristics of each local area to achieve the decorative cup design and improve the pre-compensation accuracy.

[0005] On one hand, embodiments of the present invention provide a 3D decorative cup design method incorporating planar grating patterns, comprising the following steps: Obtain the geometric model and initial planar raster pattern of the 3D decorative cup; The geometric model is subjected to feature analysis to obtain the geometric feature information of the cup surface; Based on the geometric feature information, the surface of the cup is divided into regions to obtain multiple local regions; A set of deformation compensation strategies is established, which includes geometric feature compensation strategies, injection molding process parameter compensation strategies, and material non-uniform shrinkage compensation strategies. Based on the regional geometric features and injection molding process parameters of the local area, a target compensation strategy is selected from the set of deformation compensation strategies; According to the target compensation strategy, the local pattern corresponding to the local area in the initial planar grating pattern is geometrically corrected to obtain the corrected pattern. Multiple correction patterns are integrated to obtain a pre-compensated planar grating pattern, which is used for grating film fabrication.

[0006] On the other hand, embodiments of the present invention provide a 3D decorative cup design system incorporating planar grating patterns, comprising: The data acquisition module is used to acquire the geometric model and initial planar grating pattern of the 3D decorative cup; The model feature analysis module is used to perform feature analysis on the geometric model to obtain geometric feature information of the cup surface; The region division module is used to divide the surface of the cup into regions based on the geometric feature information, thereby obtaining multiple local regions; The compensation strategy establishment module is used to establish a set of deformation compensation strategies, which includes geometric feature compensation strategies, injection molding process parameter compensation strategies, and material non-uniform shrinkage compensation strategies. The target strategy selection module is used to select a target compensation strategy from the deformation compensation strategy set based on the regional geometric features of the local area and the injection molding process parameters. The pattern geometry correction module is used to perform geometric correction on the local pattern corresponding to a local area in the initial planar grating pattern according to the target compensation strategy, so as to obtain a corrected pattern. The pre-compensation pattern integration module is used to integrate multiple correction patterns to obtain a pre-compensation planar grating pattern, which is used for grating film fabrication.

[0007] The embodiments of this application include at least the following beneficial effects: First, the geometric model and initial planar grating pattern of the 3D decorative cup are obtained. Then, feature analysis is performed on the geometric model to obtain the geometric feature information of the cup surface. The cup surface is divided into regions to obtain multiple local regions. Then, a set of deformation compensation strategies is established. Based on the regional geometric features of the local regions and the injection molding process parameters, a target compensation strategy is selected from the set of deformation compensation strategies. Finally, based on the target compensation strategy, the local pattern corresponding to the local region in the initial planar grating pattern is geometrically corrected to obtain a corrected pattern. Multiple corrected patterns are integrated to obtain a pre-compensated planar grating pattern for grating film fabrication. This allows for pre-compensation of the grating pattern by combining the features of each local region to realize the decorative cup design and improve the pre-compensation accuracy.

[0008] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the description and the drawings. Attached Figure Description

[0009] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0010] Figure 1 This is a flowchart illustrating a 3D decorative cup design method incorporating planar grating patterns according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of a 3D decorative cup design system that incorporates planar grating patterns, according to an embodiment of the present invention. Detailed Implementation

[0011] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments.

[0012] In the field of decorative cup manufacturing, to ensure that the originally flat grating pattern maintains a clear and consistent three-dimensional effect when applied to a cup with a complex shape, technicians need to perform precise deformation processing on the pattern beforehand—a process known as pre-compensation design. This work faces multiple challenges, especially given the complex and varied shapes of the cups and the uneven cooling and shrinkage of the injection molding material.

[0013] In the high-end consumer goods sector, there is a growing demand for 3D decorative mugs with unique visual effects. The core of these mugs lies in the integrated lenticular 3D patterns on their surface, which imbue the mug with a vivid sense of depth and dynamic visual variation. To achieve this effect, in-mold labeling (IML) is typically used, precisely bonding a film pre-printed with the lenticular pattern to the mug's 3D curved surface. The challenge of this process lies in ensuring that the final 3D effect accurately reflects the design intent when the originally planar 2D lenticular pattern is transformed and bonded to the 3D mug surface.

[0014] In the manufacturing process of in-mold labeling, after a flat lenticular sheet is fed into the mold cavity, it naturally stretches and deforms when molten plastic is injected and pressed against the mold surface. This deformation may have little impact on ordinary printed patterns, but for lenticular patterns that rely on precise microstructure, any stretching or compression directly alters the spacing and angle of the lenticular lines, leading to distortion in the final 3D visual effect, such as reduced three-dimensionality, blurred patterns, or unnatural distortions. Therefore, to counteract this deformation during the molding process, the original two-dimensional lenticular pattern must undergo pre-deformation processing during the design phase—a pre-compensation design—to ensure that after plastic injection and film lamination, the lenticular pattern can recover its ideal geometric state, presenting an accurate three-dimensional effect.

[0015] To enhance the grip and overall aesthetic appeal of these decorative cups, the design of the cup body is often not a simple cylinder or cone, but rather a complex shape with non-uniform curvature. For example, there may be ergonomically designed concave or convex areas in the middle of the cup body, or a unique decorative arc at the transition between the bottom and the rim. This complex, free-form surface shape makes the tensile force and deformation direction experienced by the grating film during the bonding process highly uneven. Existing methods are usually based on simplified mathematical expansions of simple geometries (such as standard cylinders or cones), and their predictive ability decreases significantly for such complex surfaces with non-uniform curvature. These methods cannot accurately capture the local tensile differences of the film in different curvature regions, resulting in poor pre-compensation effects, failing to meet the requirements of high-precision pattern bonding, and exhibiting low pre-compensation accuracy.

[0016] In the design of 3D decorative cups that incorporate planar grating patterns, it is necessary to precisely pre-compensate the initial planar grating pattern to simultaneously counteract the local tensile deformation caused by the non-uniform and complex curved surface of the cup body, as well as the secondary distortion caused by the non-linear uneven shrinkage of the injection molding material in different wall thickness and curvature areas. This ensures that the grating pattern on the final product cup body presents a highly consistent and expected three-dimensional visual effect in any position.

[0017] In view of this, this application conducts in-depth feature analysis of the geometric model of the 3D decorative cup and divides the surface of the cup into regions based on the geometric feature information, enabling customized processing for the unique geometric characteristics of each local area. For example, for a cup with complex curves and surfaces, this application can identify the curvature changes in different regions and adjust the compensation strategy accordingly. This application establishes a set of deformation compensation strategies, including geometric feature compensation strategies, injection molding process parameter compensation strategies, and material non-uniform shrinkage compensation strategies, enabling it to simultaneously address the initial tensile deformation during the in-mold application process and the secondary distortion caused by the non-uniform shrinkage of the material itself during cooling and solidification. This application can more accurately predict the final deformation of the film and perform pre-geometric corrections. Furthermore, by selecting a target compensation strategy and performing precise geometric corrections on the initial planar grating pattern, this application obtains a pre-compensated planar grating pattern, thereby ensuring that the grating pattern on the final finished cup body presents a highly consistent and expected stereoscopic visual effect in any position. This method significantly improves the design precision and visual quality of 3D decorative cups, bringing substantial technological progress to the field of 3D decorative cup manufacturing that combines in-mold grating three-dimensional patterns.

[0018] The embodiments of this application will be explained in detail below with reference to the accompanying drawings: Figure 1 This is an optional flowchart of a 3D decorative cup design method combining planar lenticular patterns provided in an embodiment of this application. Figure 1The method may include, but is not limited to, steps S101 to S107.

[0019] Step S101: Obtain the geometric model and initial planar grating pattern of the 3D decorative cup; Step S102: Perform feature analysis on the geometric model to obtain the geometric feature information of the cup surface; Step S103: Based on the geometric feature information, the surface of the cup is divided into regions to obtain multiple local regions; Step S104: Establish a set of deformation compensation strategies, which includes geometric feature compensation strategies, injection molding process parameter compensation strategies, and material non-uniform shrinkage compensation strategies. Step S105: Select a target compensation strategy from the set of deformation compensation strategies based on the local geometric features and injection molding process parameters. Step S106: According to the target compensation strategy, perform geometric correction on the local pattern corresponding to the local area in the initial planar grating pattern to obtain the corrected pattern; Step S107: Integrate multiple correction patterns to obtain a pre-compensated planar grating pattern, which is used for grating film fabrication.

[0020] Steps S101 to S107 shown in the embodiments of this application can perform grating pattern pre-compensation based on the characteristics of each local area to realize the decorative cup design and improve the pre-compensation accuracy.

[0021] In some embodiments, steps S101-S107 may involve first acquiring the geometric model and initial planar grating pattern of the 3D decorative cup. For example, the actual cup can be scanned using a 3D scanner to generate high-precision point cloud data, and then the geometric model can be constructed using reverse engineering software. The initial planar grating pattern can be generated by professional design software and imported into the system in vector or bitmap form. It is understood that a 3D decorative cup refers to a cup with a complex three-dimensional curved surface shape combined with an in-mold grating three-dimensional pattern.

[0022] Then, feature analysis is performed on the geometric model to obtain the geometric feature information of the cup surface. Curvature analysis algorithms can be used to calculate the average curvature, Gaussian curvature, etc., at various points on the cup surface to identify flat areas, convex areas, concave areas, saddle point areas, etc. Furthermore, the normal direction and tangent direction of the cup surface can be analyzed to obtain more comprehensive geometric feature information. For example, for a cup with complex curves and surfaces, its surface may contain multiple regions with drastic curvature changes; the geometric feature information of these regions is crucial for subsequent region segmentation and compensation strategy selection.

[0023] Based on geometric features, the surface of the cup is divided into multiple local regions. For example, division can be based on curvature thresholds, classifying areas with gentle curvature changes into one local region and areas with drastic curvature changes into another. Alternatively, a topology-based approach can be used to divide different functional areas of the cup (such as the rim, body, and base) into different local regions. This division allows for more refined compensation measures tailored to the deformation characteristics of different regions.

[0024] A set of deformation compensation strategies is then established, including geometric feature compensation strategies, injection molding process parameter compensation strategies, and material non-uniform shrinkage compensation strategies. Geometric feature compensation strategies can adjust the local stretching or compression ratio of the grating pattern based on the curvature, slope, and other geometric characteristics of the cup surface. Injection molding process parameter compensation strategies can predict the deformation trend of the diaphragm during injection molding based on parameters such as injection temperature, pressure, and holding time, and perform corresponding compensation. Material non-uniform shrinkage compensation strategies can consider the shrinkage differences of different materials during cooling and solidification, and pre-deform the pattern. For example, for a cup with different wall thickness areas, the material shrinkage may vary significantly, thus requiring a targeted compensation strategy.

[0025] Based on the local geometric features and injection molding process parameters, a target compensation strategy is selected from a set of deformation compensation strategies. For example, if a local area has a large curvature and high injection pressure, a strategy combining geometric stretching compensation and high-pressure injection compensation may be necessary. The selection process can be based on a pre-defined rule base or machine learning model to ensure that the selected strategy can maximally offset the deformation of the local area. For example, the rule base includes combinations of geometric features, injection molding process parameters, and the correlation between parameters and compensation strategies. Combinations of geometric features describe the geometric characteristics of a local area on the cup surface, such as radius of curvature, rate of change of wall thickness, concave surfaces, raised edges, and gradual wall thickness transition areas. Injection molding process parameters describe the conditions during the injection molding process, such as the temperature of the molten plastic and the injection pressure. Based on the local geometric features and injection molding process parameters, the correlation between parameters and compensation strategies can be used to calculate the strategy correlation degree, and the compensation strategy with the highest correlation degree can be selected as the target compensation strategy. More often, machine learning models can employ classification models, such as support vector machines, decision trees, or neural network classification models, to categorize local regions into predefined deformation types and indirectly select the corresponding compensation rules. The classification model can be trained using a large amount of historical production data, which may include the geometric features of different 3D decorative cups, injection molding process parameters, actual grating pattern deformation data after molding, and ideal compensation results verified manually or through simulation. The regional geometric features and injection molding process parameters can be used as model inputs, the classification model outputs the predicted deformation type, and the target compensation strategy corresponding to the deformation type can be selected.

[0026] Based on the target compensation strategy, the local patterns corresponding to local areas in the initial planar grating pattern are geometrically corrected to obtain the corrected pattern. For example, if the target compensation strategy indicates that a certain local area needs stretching compensation, an image processing algorithm can be used to non-uniformly stretch the local pattern to counteract the compression caused by the deformation of the cup surface. The correction process may involve adjusting microscopic geometric parameters such as the spacing, angle, and direction of the grating lines. It is understood that the initial planar grating pattern refers to the two-dimensional grating pattern designed before the in-mold bonding process, and its microstructure determines the final stereoscopic visual effect.

[0027] Finally, multiple correction patterns are integrated to obtain a pre-compensated planar grating pattern, which is used in the fabrication of the grating film. The integration process needs to ensure a smooth transition between correction patterns in different local areas to avoid visual discontinuities. For example, interpolation algorithms or boundary blending techniques can be used to seamlessly stitch together correction patterns from adjacent local areas. The pre-compensated planar grating pattern is ultimately used in the fabrication of the grating film to ensure that the grating pattern presents an ideal stereoscopic visual effect after in-mold bonding.

[0028] Through the above technical solution, this embodiment can ensure that after in-mold bonding, the pattern on the grating film can be accurately restored to its ideal state during design, thus presenting a clear, consistent, and expected three-dimensional visual effect at any position on the 3D decorative cup. This method effectively solves the problem of pattern distortion caused by complex curved surfaces and non-uniform material shrinkage in traditional designs, significantly improving the visual quality and design accuracy of the 3D decorative cup.

[0029] In some embodiments, in step S106, according to the target compensation strategy, the local pattern corresponding to the local area in the initial planar grating pattern is geometrically corrected to obtain the corrected pattern, which may include, but is not limited to, the following steps: Step S201: Obtain the injection molding material parameters for the 3D decorative cup; Step S202: Based on the injection molding material parameters, simulate the flow and cooling solidification of the molten plastic, and calculate the residual stress distribution inside the cup after solidification; Step S203: Based on the residual stress distribution, the surface of the cup is adaptively divided to obtain multiple stress-uniform micro-regions; Step S204: Extract features from the uniformly stressed micro-region to obtain stress features; Step S205: Based on the stress characteristics, generate a target compensation command. The target compensation command is used to counteract the micro-torsion caused by stress. Step S206: According to the target compensation instruction and target compensation strategy, perform geometric correction on the local pattern corresponding to the local area in the initial planar grating pattern to obtain the corrected pattern.

[0030] In some embodiments, relying solely on macroscopic geometric feature compensation, injection molding process parameter compensation, and material non-uniform shrinkage compensation may not be sufficient to completely offset the complex internal residual stresses generated during the flow and cooling solidification of the molten plastic during injection molding. These residual stresses can cause unpredictable distortions in the grating pattern at the microscopic level, thereby affecting the visual effect and three-dimensional coherence of the final 3D decorative cup.

[0031] To do this, the injection molding material parameters of the 3D decorative cup can be obtained first. These include melt flow index, specific heat capacity, thermal conductivity, density, shrinkage rate, elastic modulus, Poisson's ratio, and glass transition temperature. These parameters are crucial for accurately simulating the flow, cooling, and solidification processes of molten plastic within the mold. Their purpose is to provide precise input data for subsequent injection molding process simulations, ensuring the reliability of the simulation results.

[0032] Then, based on the injection molding material parameters, the flow and cooling solidification of the molten plastic are simulated to calculate the residual stress distribution inside the cup after solidification. This can be done using computer-aided engineering (CAE) software (e.g., Moldflow, Abaqus, etc.). The simulation covers multiple stages of the injection molding process, including molten plastic filling the mold cavity, holding pressure, and cooling solidification. During the simulation, factors such as the viscoelastic behavior of the material, thermal conduction, phase transformation, and volume shrinkage are considered. Through simulation, the internal stress state, i.e., the residual stress distribution, can be predicted inside the cup during the cooling solidification process due to factors such as non-uniform cooling, inconsistent volume shrinkage, and molecular orientation. The purpose is to quantify the stress state inside the cup, identify potential stress concentration areas and stress gradients, and provide a basis for subsequent pattern correction.

[0033] Based on the residual stress distribution, the surface of the cup is then adaptively divided into multiple micro-regions with uniform stress. Specific algorithms (e.g., gradient analysis, cluster analysis, or finite element mesh refinement techniques) can be used to divide the cup surface into several smaller regions with relatively uniform stress distribution. Within each micro-region, the magnitude and direction of the residual stress vary little and can be considered approximately uniform. The aim is to achieve fine-grained management of the cup surface deformation, ensuring that subsequent compensation commands can be accurately adjusted for local stress characteristics.

[0034] Feature extraction is performed on uniformly stressed micro-regions to obtain stress characteristics, such as the magnitude and direction of principal stresses, shear stress components, stress gradients, and stress concentration factors. These features can quantify the type and extent of microscopic distortion that stress within the micro-region may cause to the grating pattern. The purpose is to provide quantified input for generating precise target compensation commands.

[0035] Based on stress characteristics, target compensation instructions are generated to counteract the microscopic distortions caused by stress. A specific set of geometric transformation parameters can be generated as target compensation instructions for the stress characteristics of each uniformly stressed micro-region. These parameters may include local scaling factors, rotation angles, shear deformation, and distortion correction amounts, aiming to counteract the microscopic distortions caused by residual stress by performing reverse geometric corrections on the grating pattern. The goal is to ensure that the grating pattern maintains its intended geometric shape and optical performance in the final product.

[0036] Finally, based on the target compensation command and the target compensation strategy, the local patterns corresponding to local areas in the initial planar grating pattern are geometrically corrected to obtain the corrected pattern. The target compensation command and the target compensation strategy can be fused. This fusion can be achieved through weighted averaging, superposition, or iterative optimization. Based on the fused comprehensive compensation scheme, the patterns of corresponding local areas in the initial planar grating pattern are precisely geometrically transformed to obtain a corrected pattern that effectively compensates for various deformation factors (including internal residual stress). The aim is to obtain a highly accurate pre-compensated planar grating pattern for fabricating high-quality grating films.

[0037] To illustrate this technical solution more clearly, a specific example is used below. Suppose we need to design a 3D decorative cup made of polycarbonate (PC) material through injection molding. First, obtain detailed injection molding parameters for the PC material, including its viscosity curve, specific heat capacity, coefficient of thermal expansion, shrinkage rate, and elastic modulus. Then, using professional injection molding simulation software (e.g., Autodesk Moldflow Insight), input the geometric model of the 3D decorative cup and the PC material parameters to simulate the entire injection molding process, including the filling, holding, and cooling stages. Through simulation, the residual stress distribution inside the cup after curing can be accurately calculated, including the principal stress directions and magnitudes. Subsequently, based on the simulated residual stress distribution map, the system adaptively meshes the cup surface, dividing it into hundreds or even thousands of stress-uniform micro-regions. Within each micro-region, the magnitude and direction of residual stress vary within a preset threshold. Next, the stress characteristics of each stress-uniform micro-region are extracted; for example, identifying whether the region is under tensile, compressive, or shear stress, as well as the principal directions and magnitudes of these stresses. Based on these stress characteristics, a set of specific target compensation instructions are generated. For example, for a micro-region affected by tensile stress, an instruction for slight scaling along the tensile direction is generated; for a region affected by shear stress, a instruction for slight shear deformation is generated. These instructions aim to precisely counteract the microscopic distortions caused by residual stress. Finally, these target compensation instructions generated for residual stress are integrated with the aforementioned target compensation strategies (e.g., geometric feature compensation, injection molding process parameter compensation, etc.) to form a comprehensive geometric correction scheme. According to this comprehensive scheme, the pattern of the corresponding local region in the initial planar grating pattern is geometrically corrected, ultimately obtaining a pre-compensated planar grating pattern for grating film fabrication.

[0038] Through the above technical solution, this embodiment achieves quantitative analysis of the residual stress distribution inside the cup body by acquiring injection molding material parameters and simulating the process, thus overcoming the shortcomings in handling complex internal stresses. By adaptively dividing the stress-uniform micro-regions and extracting stress features, the compensation is ensured to be refined and localized, allowing the geometric correction of the grating pattern to specifically counteract micro-deformations. Therefore, the final corrected pattern can better adapt to the actual deformation of the cup body, effectively suppressing the generation of optical defects such as moiré fringes and visual artifacts, thereby improving the three-dimensional continuity and overall aesthetics of the 3D decorative cup and providing users with a better visual experience.

[0039] In some embodiments, step S205, generating a target compensation command based on stress characteristics, may include, but is not limited to, the following steps: Step S301: Obtain the actual local physical property data of the injection molding material in the micro-region with uniform stress. The actual local physical property data includes material temperature, pressure and cooling rate. Step S302: Determine the stress-strain conversion coefficient based on the actual local physical property data; Step S303: Generate initial compensation command based on stress-strain conversion coefficient; Step S304: Based on the stress characteristics, randomly perturb the initial compensation command to generate multiple candidate compensation commands; Step S305: Perform grating line micromorphology correction simulation on the selected compensation command to obtain simulation results; Step S306: Based on the simulation results, the micromorphological consistency of the grating lines is judged to obtain the judgment result; Step S307: If the judgment result is that the consistency standard is met, then the initial compensation instruction is used as the target compensation instruction.

[0040] In some embodiments, generating compensation instructions directly based solely on stress characteristics may not adequately address the differences in the actual physical properties of the injection-molded material in different local areas, as well as the complex nonlinear relationship between stress and the micro-morphological distortion of the grating lines. This can result in insufficient accuracy in the generated compensation instructions, failing to completely eliminate micro-distortions, and consequently affecting the visual consistency and clarity of the grating pattern on the 3D decorative cup.

[0041] To this end, we can first obtain the actual local physical property data of the injection-molded material in a micro-region with uniform stress. Actual local physical property data refers to the instantaneous or average state parameters experienced by the material in a specific micro-region with uniform stress during the injection molding process. This data includes material temperature, pressure, and cooling rate. These data can be obtained through real-time monitoring using micro-sensors installed inside the injection mold, or through prediction using high-precision injection molding process simulation software. The purpose is to provide accurate local material state input for subsequent stress-strain transformation.

[0042] Then, based on the actual local physical property data, the stress-strain conversion coefficient is determined. Based on the principles of materials mechanics and thermodynamics, combined with the obtained local temperature, pressure, and cooling rate, the proportional relationship of material deformation under specific stress in that region can be calculated as the stress-strain conversion coefficient. This coefficient reflects the mechanical response characteristics of the material under different local conditions; for example, the material may be more easily deformed at higher temperatures, while its stiffness may increase under high pressure.

[0043] An initial compensation command is generated based on the stress-strain conversion factor. Using the established stress-strain conversion factor, the calculated residual stress distribution (or stress characteristics) can be converted into an initial correction to the microstructure of the grating lines. This initial compensation command aims to initially counteract the micro-distortions caused by residual stress, such as adjusting the local spacing, orientation, or curvature of the grating lines.

[0044] Based on the stress characteristics, the initial compensation command is then randomly perturbed to generate multiple candidate compensation commands. This aims to explore the optimization space surrounding the initial compensation command. By introducing controlled random variations, a series of potentially better compensation schemes are generated. The random perturbation can be parameterized based on the type and degree of stress characteristics. For example, for tensile stress in a specific direction, the compensation amount of the gate spacing can be randomly increased or decreased within a small range in that direction.

[0045] Simulations were performed to correct the microstructure of the grating lines under different compensation commands, and the simulation results were obtained. Finite element analysis, optical tracing, or diffraction theory can be used to evaluate the impact of the compensated grating structure on light propagation, diffraction efficiency, and visual effects. This allows for the prediction of the final microstructure of the grating lines on the cup surface and its optical performance after applying different compensation commands.

[0046] Based on the simulation results, the micromorphological consistency of the grating lines is assessed, and the assessment results are obtained to evaluate whether the grating lines after compensation simulation meet the preset visual effect and structural integrity standards. The criteria for judging micromorphological consistency may include the uniformity of grating line spacing, the continuity of orientation, the stability of diffraction efficiency, and the avoidance of moiré fringes or visual artifacts.

[0047] If the judgment result is that the consistency criteria are met, the initial compensation command will be used as the target compensation command. This means that if, after random perturbation and simulation verification, it is found that the initial compensation command itself, or its slightly adjusted version, can meet all the preset micromorphological consistency criteria, then the command is confirmed as the most effective compensation scheme.

[0048] To illustrate this technical solution more clearly, a specific example is used below. Suppose that during the injection molding process of a 3D decorative cup, the shoulder area of ​​the cup body experiences a faster cooling rate, resulting in a lower temperature of the injection-molded material and higher residual stress in this area. First, temperature and pressure sensors are installed in the shoulder area of ​​the mold to acquire data on the actual local temperature, pressure, and cooling rate during the curing process. Based on this data, combined with the material's mechanical model, the stress-strain conversion coefficient for this area can be accurately calculated. For example, under low temperature and high pressure, the elastic modulus of the material may be higher, and the corresponding stress-strain conversion coefficient will be adjusted accordingly. Subsequently, based on the stress characteristics of this area (e.g., tensile stress along the circumference), an initial compensation command is generated using the calculated stress-strain conversion coefficient. This command might instruct a slight expansion of the grating line spacing in the shoulder area along the circumference. To verify and optimize this command, a small-scale random perturbation can be applied to the initial compensation command to generate multiple candidate commands; for example, the expansion amount can be fine-tuned within ±5% of the initial value. Next, these candidate instructions undergo grating line micromorphology correction simulation to simulate the propagation and diffraction effects of light on the compensated grating structure, and evaluate their moiré fringe intensity, visual artifact intensity, etc. Finally, based on the simulation results, the micromorphological consistency of the grating lines is judged. For example, it is determined whether the moiré fringe suppression factor and visual artifact suppression factor meet preset thresholds, and whether the virtual stereo disparity change is within a coherence threshold. If the initial compensation instruction or a fine-tuned version thereof can meet all consistency criteria, it is selected as the final target compensation instruction to guide the fabrication of the grating film, thereby ensuring that the 3D pattern in the shoulder area maintains a high degree of visual coherence and clarity, effectively avoiding pattern distortion caused by local stress.

[0049] Through the above technical solution, this embodiment considers the actual local physical properties of the injection-molded material and combines it with the stress-strain conversion coefficient, making the generation of compensation commands more targeted and scientific. Furthermore, the introduced random disturbance, correction simulation, and consistency judgment mechanisms provide effective means for optimizing and verifying compensation commands, significantly improving the accuracy and reliability of compensation. Therefore, it can effectively avoid problems such as visual artifacts, moiré fringes, or discontinuous three-dimensionality caused by insufficient or excessive compensation, thereby ensuring high-quality consistency and stability of the grating pattern on complex curved surfaces in the 3D decorative cup.

[0050] In some embodiments, in step S304, the initial compensation command is randomly perturbed according to the stress characteristics to generate multiple candidate compensation commands, which may include, but is not limited to, the following steps: Based on the stress characteristics, determine the type and degree of micro-twist that occurs in the grating lines within the uniformly stressed micro-region; Based on the type and degree of micro-twist and the actual local physical characteristics data, set the parameter space boundary of the random perturbation; Based on the parameter space boundary, multiple candidate compensation instructions are generated.

[0051] In some embodiments, the type and degree of micro-twist occurring in the grating lines within a uniformly stressed micro-region can be determined first based on stress characteristics, aiming to provide accurate deformation information for subsequent compensation command generation. The type of micro-twist can include various deformation modes such as stretching, compression, shearing, and bending, while the degree of micro-twist quantifies the severity of these deformations.

[0052] Then, based on the type and degree of micro-twist and actual local physical property data, a parameter space boundary for random perturbation is set. This parameter space boundary defines the generation range of candidate compensation commands, ensuring that the generated compensation commands can specifically address specific types of micro-twist and take into account the material's response characteristics during the actual injection molding process. For example, for tensile deformation, the parameter space boundary may favor generating contractile compensation commands; for compressive deformation, it may favor generating expansionary compensation commands.

[0053] Then, based on the parameter space boundary, multiple candidate compensation commands are generated. These candidate compensation commands are variants of the initial compensation command after random perturbation within a specific parameter space. Each of them represents a possible micromorphological correction scheme to counteract the micro-torsion caused by stress. By perturbing within a defined and meaningful parameter space, the efficiency and accuracy of generating effective candidate compensation commands can be improved.

[0054] This embodiment first determines the type and degree of microscopic distortion of the grating lines based on stress characteristics, ensuring that subsequent random perturbations are no longer blind but have a clear direction and target. Then, by setting parameter space boundaries based on actual local physical characteristic data, the perturbation range is further limited to a physically reasonable and effective interval. This targeted and constrained random perturbation allows the generated candidate compensation instructions to more effectively cover the potential optimization space, thereby increasing the probability of finding the optimal compensation scheme and avoiding the generation of a large number of invalid or unrealistic compensation instructions.

[0055] Through the above technical solution, this embodiment accurately identifies the type and degree of micro-twist and sets reasonable perturbation parameter space boundaries in conjunction with actual physical characteristic data. This ensures that the generated candidate compensation instructions are more targeted, thereby reducing the generation of invalid or inefficient compensation schemes. This not only optimizes the subsequent simulation process for micro-morphological correction of grating lines and reduces the consumption of computing resources, but also improves the accuracy and reliability of the final target compensation instructions, enabling the grating pattern of the 3D decorative cup to better maintain its expected visual effect and three-dimensionality after injection molding.

[0056] In some embodiments, step S305 involves performing a grating line micromorphology correction simulation on the selected compensation command to obtain the simulation results, which may include, but is not limited to, the following steps: The microscopic geometric parameters of the grating lines and the local geometric features of the cup surface are obtained within a micro-region with uniform stress. Based on microscopic geometric parameters and local geometric features, a multi-angle virtual observation path is constructed to simulate the propagation path of light on the grating microstructure and the surface of the cup. Based on the multi-angle virtual observation path, the projection pattern of the grating lines on the surface of the cup is analyzed by parameters to obtain the moiré fringe intensity, moiré fringe spatial frequency, visual artifact intensity, and visual artifact spatial frequency. Calculate the moiré fringe suppression factor based on the moiré fringe intensity and the moiré fringe spatial frequency; The visual artifact suppression factor is calculated based on the visual artifact intensity and the visual artifact spatial frequency. The moiré fringe suppression factor and the preset moiré fringe suppression threshold are compared to obtain the first comparison result; The visual artifact suppression factor is compared with the preset visual artifact suppression threshold to obtain a second comparison result; Simulation results are generated based on the first and second comparison results.

[0057] In some embodiments, the microscopic geometric parameters of the grating lines within a uniformly stressed micro-region and the local geometric features of the cup surface can be obtained first. The microscopic geometric parameters may include grating line width, depth, period, etc., while the local geometric features may include curvature, slope, etc. These parameters form the basis for constructing an accurate simulation environment.

[0058] Then, based on the microscopic geometric parameters and local geometric features, a multi-angle virtual observation path is constructed. This aims to create a virtual optical environment that simulates how light interacts and propagates with the grating microstructure and the cup surface when observed by the human eye or a sensor from different angles. The multi-angle virtual observation path is used to simulate the propagation path of light on the grating microstructure and the cup surface. The construction of this multi-angle virtual observation path can comprehensively capture the visual effects of the grating pattern from different perspectives, providing data support for subsequent parameter analysis.

[0059] Based on a multi-angle virtual observation path, parametric analysis is performed on the projection pattern of the grating lines onto the surface of the cup to obtain the moiré fringe intensity, moiré fringe spatial frequency, visual artifact intensity, and visual artifact spatial frequency. This aims to quantify the visual defects of the grating pattern on the curved surface. The moiré fringe intensity and spatial frequency are used to evaluate the significance and distribution density of interference fringes caused by the geometric mismatch between the grating and the curved surface; the visual artifact intensity and spatial frequency are used to evaluate the degree of visual distortion caused by other non-ideal optical effects (such as diffraction and scattering).

[0060] Next, the moiré fringe suppression factor is calculated based on the moiré fringe intensity and spatial frequency. The moiré fringe suppression factor is an indicator that measures the degree to which moiré fringes are suppressed in a grating pattern. Its calculation can be based on a moiré fringe visibility model, aiming to quantify the effectiveness of the correction scheme in eliminating or mitigating moiré fringes. Then, the visual artifact suppression factor is calculated based on the visual artifact intensity and spatial frequency. The visual artifact suppression factor is used to evaluate the effectiveness of the correction scheme in reducing visual artifacts; its calculation can be based on the human eye's perceptual sensitivity to different types of artifacts.

[0061] The first comparison result is obtained by comparing the moiré fringe suppression factor with the preset moiré fringe suppression threshold. The second comparison result is obtained by comparing the visual artifact suppression factor with the preset visual artifact suppression threshold. These comparisons aim to determine whether the simulated correction effect meets the expected visual quality standard. The preset moiré fringe suppression threshold and the preset visual artifact suppression threshold can be determined based on human visual perception characteristics, product quality requirements, or expert experience. During threshold determination, under normal lighting conditions, a multi-angle virtual observation path can be constructed by simulating the propagation path of light on the grating microstructure and the cup surface. The projection pattern of the grating lines on the cup surface is analyzed along this multi-angle virtual observation path to identify the intensity of the moiré fringes, such as contrast and average brightness deviation, and to identify the spatial frequency of the moiré fringes, such as the number of fringes per millimeter. Multiple light simulation experiments can be conducted, and the intensity and spatial frequency of multiple moiré fringes can be statistically analyzed to calculate a weighted average as the preset moiré fringe suppression threshold. Meanwhile, by analyzing the projection pattern of the grating lines on the curved surface of the cup, the intensity and spatial frequency of visual artifacts are identified, and statistical analysis is performed to calculate the weighted average as the preset visual artifact suppression threshold.

[0062] Finally, simulation results are generated based on the first and second comparison results. These simulation results comprehensively reflect the effectiveness of the candidate compensation commands in correcting the microstructure of the grating lines, providing a basis for subsequent judgments on microstructure consistency.

[0063] This embodiment constructs a sophisticated optical simulation environment, enabling accurate prediction of the visual effects of different candidate compensation commands on the micro-morphology correction of grating lines. Specifically, by acquiring the micro-geometric parameters of the grating lines and the local geometric features of the cup surface, real-world input data is provided for the simulation. The construction of multi-angle virtual observation paths allows the simulation to comprehensively cover various observation conditions, thereby capturing various visual phenomena that may occur in practical applications of the grating pattern. Parameter analysis of the projected pattern quantifies key visual defects such as moiré fringes and visual artifacts, providing an objective basis for evaluating the correction effect. The calculation of moiré fringe suppression factors and visual artifact suppression factors further transforms these quantified indicators into comparable performance parameters. By comparing these suppression factors with preset thresholds, it can be determined whether the candidate compensation command can effectively eliminate or mitigate micro-distortions caused by stress, thereby ensuring that the corrected grating pattern meets visual consistency standards. This simulation mechanism allows for virtual testing and screening of multiple compensation commands before actual fabrication of the grating film, significantly improving design efficiency and success rate.

[0064] Through the above technical solution, this embodiment, by constructing a multi-angle virtual observation path, can comprehensively simulate the propagation of light on complex curved gratings, thereby accurately predicting potential visual defects such as moiré fringes and visual artifacts. By calculating the moiré fringe suppression factor and the visual artifact suppression factor and comparing them with preset thresholds, the correction effect of different compensation instructions can be objectively judged, avoiding the inefficiency of relying on experience or repeated trial and error. This embodiment can effectively select the optimal compensation instruction, ensuring that the corrected grating pattern presents a high-quality, visually defect-free three-dimensional effect on the complex curved surface of the 3D decorative cup, significantly improving the product's visual appeal and manufacturing precision.

[0065] In some embodiments, in step S306, the micromorphological consistency of the grating lines is judged based on the simulation results to obtain the judgment result, which may include, but is not limited to, the following steps: Step S401: Obtain the microscopic geometric parameters of the grating lines in the stress-uniform micro-region and the local geometric features of the cup surface; Step S402: Calculate the change in virtual stereo disparity based on the microscopic geometric parameters and the human eye's stereo perception sensitivity curve; Step S403: Compare the virtual stereo disparity change with the preset stereo coherence threshold to obtain a third comparison result; Step S404: Calculate the diffraction efficiency based on the microscopic geometric parameters and the optical diffraction characteristics of the grating microstructure; Step S405: Compare the diffraction efficiency with the preset sharpness threshold to obtain the fourth comparison result; Step S406: Calculate the projection deformation of the grating lines on the surface of the cup based on the local geometric features; Step S407: Compare the projected deformation with the preset local distortion threshold of the grid line to obtain the fifth comparison result; Step S408: Based on the third comparison result, the fourth comparison result, the fifth comparison result, and the simulation result, determine whether the grating lines meet the micromorphological consistency standard and obtain the judgment result.

[0066] In some embodiments, the microscopic geometric parameters of the grating lines within a uniformly stressed micro-region and the local geometric features of the cup surface can be obtained first. Simultaneously, based on the microscopic geometric parameters and the human eye's stereoscopic perception sensitivity curve, the virtual stereoscopic parallax variation is calculated. The human eye's stereoscopic perception sensitivity curve describes the human eye's ability to perceive different parallax magnitudes, i.e., the minimum parallax variation that the human eye can distinguish at different viewing distances and angles. The virtual stereoscopic parallax variation refers to the parallax variation produced by the grating pattern at different viewing angles under simulated observation conditions; this parallax variation reflects the coherence and comfort of the 3D visual effect. The virtual stereoscopic parallax variation is then compared with a preset stereoscopic coherence threshold to determine whether the 3D effect is smooth and natural, avoiding any sense of jumpiness or discomfort, thus obtaining a third comparison result. The determination of the preset stereoscopic coherence threshold can be calibrated and optimized using a large amount of experimental data (e.g., human visual evaluation of samples with different degrees of deformation) and multiphysics simulation (e.g., a combination of optical and mechanical simulations). For example, through repeated trial production and quality inspection, feedback on the stereoscopic visual effect of the product under different compensation schemes is collected, and it is correlated with the results of optical simulation and mechanical simulation, gradually converging to a threshold range that can predict and ensure the visual consistency of the product.

[0067] Then, based on the microscopic geometric parameters and the optical diffraction characteristics of the grating microstructure, the diffraction efficiency is calculated. The optical diffraction characteristics of the grating microstructure refer to the diffraction phenomena that occur when light passes through the grating structure, including the diffraction angle, diffraction order, and energy distribution of each order. Diffraction efficiency measures the ability of a grating to convert incident light energy into light energy of a specific diffraction order; it directly relates to the brightness and sharpness of the grating pattern. The diffraction efficiency is compared with a preset sharpness threshold to ensure that the grating pattern has sufficient brightness and sharpness in the final product, resulting in a fourth comparison result. In determining the preset sharpness threshold, the basic requirements for the sharpness of the grating pattern can be determined based on the overall design goals and desired visual effects of the 3D decorative cup. For example, at a specific viewing distance, what level of sharpness is required for the lines of the grating pattern to present a clear three-dimensional effect? ​​Combining the basic requirements with the human eye's stereoscopic perception sensitivity curve, it is ensured that the set threshold matches the actual perceptual ability of the human eye. For example, the minimum number of line pairs / millimeters that the human eye can distinguish at the viewing distance set by the basic requirements can be used as the preset sharpness threshold. The actual visual effects corresponding to different spatial frequency values ​​are verified by creating physical samples and conducting subjective visual evaluations, or by using high-precision optical measurement equipment to objectively measure the actual grating pattern. Through repeated trial production and quality inspection, a correlation between objective measurement data and subjective visual perception can be established, thereby calibrating and optimizing the preset sharpness threshold.

[0068] Since the surface of a cup is typically curved, the initial planar grating pattern will undergo projection deformation after being applied to the curved surface. This deformation may cause local twisting, stretching, or compression of the grating lines. The projection deformation of the grating lines on the cup surface can be calculated based on local geometric features. This projection deformation is then compared with a preset local distortion threshold to assess the geometric integrity of the grating lines on the curved surface, avoiding visible distortion, thus yielding the fifth comparison result. In determining the preset local distortion threshold, the threshold setting needs to meet the visual requirement of "high consistency" of the grating pattern on the final product surface of the 3D decorative cup. This means that regardless of the observer's angle or position on the cup, a continuous, repeating geometric texture should appear to have the same size, depth, and clarity. Excessive stretching of the pattern in local areas leading to a loss of three-dimensionality, or compression deformation causing visual abruptness, will be considered product defects. The threshold can be set through extensive experimental data, simulation analysis results, and research on the characteristics of human visual perception. For example, by performing actual injection molding and visual evaluation on grating patterns with different degrees of distortion, and combining simulation methods such as finite element analysis, the minimum degree of distortion that the human eye can tolerate can be determined, thereby setting a preset threshold for local distortion of the grating lines.

[0069] Based on the third, fourth, and fifth comparison results and the simulation results, it is determined whether the grating lines meet the micromorphological consistency standard. The judgment result is obtained to ensure that the corrected grating pattern can present a high-quality, artifact-free, three-dimensional, and clear visual effect on the 3D decorative cup.

[0070] Through the above technical solution, this embodiment can make a more comprehensive and accurate judgment on the microscopic morphological consistency of the grating lines, significantly improving the visual quality of the 3D decorative cup pattern. This embodiment effectively avoids problems such as inconsistent three-dimensionality, image blurring, or local distortion, ensuring that the final generated pre-compensated planar grating pattern can better adapt to the complex curved surface of the 3D decorative cup, thereby providing consumers with a higher quality and more immersive 3D visual experience.

[0071] In some embodiments, after obtaining the microscopic geometric parameters of the grating lines within a stress-uniform micro-region, the method may further include, but is not limited to, the following steps: Step S501: Perform multi-point laser scanning measurement on the surface of the cup to obtain the three-dimensional morphology data of the grating film on the surface of the cup; Step S502: Based on the three-dimensional topography data, identify the target deformation information of the local area of ​​the grating film. The target deformation information includes wrinkle deformation information, bubble deformation information and stretching deformation information. Step S503: Correct the microscopic geometric parameters based on the target deformation information.

[0072] In some embodiments, when the grating film is attached to the surface of a 3D decorative cup, it may be affected by various factors such as the injection molding process, material properties, and the geometry of the cup, resulting in local deformation of the grating film on the cup surface, such as wrinkles, bubbles, or stretching. These actual deformations can cause deviations between the preset or initially acquired microscopic geometric parameters and the actual morphology of the grating film, thereby affecting the accuracy of subsequent microscopic morphology consistency judgments. Ultimately, this may result in the correction pattern failing to completely eliminate visual artifacts or moiré fringes, affecting the final visual effect of the 3D decorative cup.

[0073] To achieve this, multi-point laser scanning measurements can be performed on the surface of the cup to obtain the three-dimensional morphology data of the grating film on the cup surface, aiming to acquire the actual three-dimensional morphology of the grating film on the cup surface. Multi-point laser scanning measurement is a non-contact, high-precision measurement technique. By emitting a laser beam and receiving the reflected light, the three-dimensional coordinate data of each point on the grating film on the cup surface can be accurately acquired, thereby constructing the three-dimensional morphology data of the grating film on the cup surface. This three-dimensional morphology data can truly reflect the actual geometric state of the grating film after bonding, including any possible local deformations.

[0074] Then, based on the three-dimensional topography data, the target deformation information of local regions of the grating film is identified. This target deformation information includes wrinkle deformation, bubble deformation, and tensile deformation. By analyzing the acquired three-dimensional topography data, various local deformations of the grating film on the cup surface are detected and quantified. Wrinkle deformation information typically manifests as abrupt changes in curvature and material accumulation in local areas; bubble deformation information manifests as bulges and boundary gradients in local areas; and tensile deformation information manifests as the strain rate and tensile direction in local areas. These deformation information are the main causes of distortion in the microscopic geometric parameters of the grating lines.

[0075] Then, based on the target deformation information, the micro-geometric parameters are corrected. For example, if wrinkles are detected in a certain area, the micro-geometric parameters such as the period, depth, or tilt angle of the grating lines in that area need to be adjusted according to the degree and direction of the wrinkles to better reflect the actual physical state. In this way, the influence of actual deformation on the accuracy of micro-geometric parameters can be eliminated or reduced, providing a more reliable input for subsequent judgment of the consistency of the micro-morphology of the grating lines.

[0076] To illustrate this technical solution more clearly, a specific example is used below. Suppose that after the in-mold bonding process is completed, an inspection of a 3D decorative cup reveals slight wrinkles in the grating film in a localized area of ​​its surface. This embodiment first performs multi-point laser scanning measurements on the cup surface to acquire its three-dimensional morphological data. By analyzing this data, the system can accurately identify the wrinkle deformation information in this localized area, including the depth, width, and direction of the wrinkles. Subsequently, the system corrects the micro-geometric parameters (e.g., grating period, depth, or tilt angle) of the grating lines in this area based on this wrinkle deformation information. For example, if the wrinkles cause local compression of the grating lines, the correction factor will adjust the grating period accordingly, allowing it to better adapt to the actual morphology after correction. The corrected micro-geometric parameters will be used for subsequent grating line micro-morphological consistency judgment, thereby ensuring that even with actual deformation, the final generated corrected pattern can present the expected 3D visual effect in the wrinkled area, effectively avoiding visual artifacts and moiré fringes.

[0077] Through the above technical solution, this embodiment can significantly improve the accuracy of judging the consistency of the micro-morphology of the grating lines by accurately correcting the micro-geometric parameters, thereby optimizing the generation of the correction pattern, effectively suppressing the generation of moiré fringes and visual artifacts, and ultimately improving the overall visual effect and product quality of the 3D decorative cup.

[0078] In some embodiments, in step S503, correcting the micro-geometric parameters based on the target deformation information may include, but is not limited to, the following steps: Step S601: Based on the fold deformation information, determine the local curvature change and material accumulation degree of the folded area; Step S602: Calculate the wrinkle correction factor based on the local curvature change and the degree of material accumulation; Step S603: Determine the local bulge height and boundary gradient of the bubble region based on the bubble deformation information; Step S604: Calculate the bubble correction factor based on the local bulge height and boundary gradient; Step S605: Determine the local strain rate and tensile direction of the tensile region based on the tensile deformation information; Step S606: Calculate the tensile correction factor based on the local strain rate and tensile direction; Step S607: The wrinkle correction factor, bubble correction factor and stretch correction factor are fused to obtain a comprehensive correction factor; Step S608: Correct the micro-geometric parameters according to the comprehensive correction factor.

[0079] In some embodiments, the surface of the cup may simultaneously exhibit multiple types of deformation, such as wrinkles, bubbles, and stretching. Each of these deformations possesses unique physical properties and mechanisms of influence on the microstructure of the grating. If only a generalized correction method is employed, it may be difficult to accurately counteract the microscopic distortions caused by various deformations, thereby affecting the visual consistency and overall aesthetics of the final grating pattern.

[0080] To this end, the local curvature changes and material accumulation degree of the wrinkled region can be determined first based on the wrinkle deformation information. Wrinkle deformation information refers to the local bulges or depressions formed on the surface of the grating film due to pressure or uneven contraction. Its characteristic is a significant change in local curvature, accompanied by material accumulation or sparseness in specific areas. By analyzing the local curvature changes and material accumulation degree of the wrinkled region, the influence of wrinkles on the microstructure of the grating lines can be quantified. For example, areas with large curvature changes may lead to more severe bending or twisting of the grating lines, while the degree of material accumulation may affect the effective thickness and optical performance of the grating. Furthermore, a wrinkle correction factor can be calculated based on the local curvature changes and material accumulation degree to counteract the influence of wrinkles on the geometric parameters of the grating lines (such as line spacing, depth, and tilt angle).

[0081] Then, based on the bubble deformation information, the local bulge height and boundary gradient of the bubble region are determined. Bubble deformation information refers to the local bulges formed between the grating film and the cup surface due to gas retention. The local bulge height of the bubble region directly reflects the size and degree of bulging of the bubble, while the boundary gradient describes the steepness of the bubble edge. These parameters are crucial for evaluating the impact of bubbles on the optical performance and visual effects of the grating lines. For example, a high bulge height and a large boundary gradient may cause irregular refraction or diffraction of light in the bubble region, resulting in visual artifacts. A bubble correction factor is then calculated based on the local bulge height and boundary gradient. The bubble correction factor is used to correct the geometric parameters of the grating lines within the bubble region to mitigate their adverse effects on visual effects.

[0082] Next, based on the tensile deformation information, the local strain rate and tensile direction of the tensile region are determined. Tensile deformation information refers to the local stretching or deformation that occurs during the bonding process of the grating film due to uneven stress. The local strain rate of the tensile region describes the degree of deformation of the material in a specific direction, while the tensile direction indicates the main direction of deformation. This information is crucial for understanding how stretching changes the period and orientation of the grating lines. For example, stretching along the grating line direction may lead to an increase in the grating line spacing, while stretching perpendicular to the grating line direction may lead to a narrowing of the grating lines. Based on the local strain rate and tensile direction, a stretching correction factor is calculated. The stretching correction factor is used to adjust the geometric parameters of the grating lines within the stretched region to restore their original design shape.

[0083] The wrinkle correction factor, bubble correction factor, and stretching correction factor are fused to obtain a comprehensive correction factor. The purpose of this fusion process is to comprehensively consider the effects of various deformations when multiple deformations may exist in the same local area, and to generate a unified and coordinated correction instruction. This comprehensive correction factor can more comprehensively and accurately reflect the overall geometric correction amount required for the local area.

[0084] Finally, the micro-geometric parameters are corrected based on a comprehensive correction factor. This comprehensive correction factor is applied to adjust the micro-geometric parameters of the grating lines, such as the grating line period, grating line depth, grating line width, grating line tilt angle, and grating line direction, to counteract the micro-distortions caused by various deformations such as wrinkles, bubbles, and stretching, ensuring the visual consistency and optical performance of the grating pattern on the cup surface.

[0085] To illustrate this technical solution more clearly, a specific example is used below. Suppose that in a local area of ​​a 3D decorative cup, multi-point laser scanning measurements reveal both slight wrinkles and a tiny bubble in the grating film. First, based on the wrinkle deformation information, the system analyzes the local curvature changes and material buildup in the wrinkled area. For example, it detects a 5% decrease in the radius of curvature in a specific direction and a 2% increase in material thickness. Based on this data, a wrinkle correction factor is calculated, which may indicate the need to locally reduce the grating line spacing in that area by 0.5 micrometers and adjust its tilt angle. Simultaneously, based on the bubble deformation information, the system determines the local bulge height and boundary gradient of the bubble area. For example, the bubble center bulges by 0.1 millimeters, and the boundary gradient is 10 degrees / millimeters. Based on this data, a bubble correction factor is calculated, which may indicate the need to increase the grating line depth in the bubble center area by 0.2 micrometers and adjust its direction to compensate for light refraction. Subsequently, these two correction factors (wrinkle correction factor and bubble correction factor) are sent to the fusion processing module. In this module, a comprehensive correction factor can be obtained by weighting and fusing data according to preset weights (e.g., 0.6 for the visual impact of wrinkles and 0.4 for bubbles) or through a more complex model (such as a neural network). For example, the fusion result might indicate that in this local area, the grating line spacing needs to be reduced by 0.3 micrometers, the depth increased by 0.1 micrometers, and specific directional adjustments made. Finally, based on this comprehensive correction factor, the corresponding local pattern in the initial planar grating pattern of this local area is geometrically corrected, thereby generating a corrected pattern that can effectively counteract the combined effects of wrinkles and bubbles, ensuring that the grating pattern in this area maintains high visual consistency and clarity.

[0086] Through the above technical solution, this embodiment, by independently analyzing and calculating corresponding correction factors for specific deformation types such as wrinkles, bubbles, and stretching, can more accurately capture the unique influence of various deformations on the microstructure of grating lines. Furthermore, by fusing these correction factors, the comprehensiveness and coordination of correction instructions are ensured under complex deformation scenarios, effectively avoiding problems of local over-correction or under-correction. Therefore, the final corrected pattern can more accurately counteract the microscopic distortions caused by multiple deformations, thereby significantly improving the visual consistency, clarity, and three-dimensionality of the grating pattern on the surface of the 3D decorative cup, reducing the generation of moiré fringes and visual artifacts, and ultimately enhancing the overall aesthetic value and market competitiveness of the product.

[0087] In some embodiments, step S607 involves fusing the wrinkle correction factor, bubble correction factor, and stretch correction factor to obtain a comprehensive correction factor, which may include, but is not limited to, the following steps: Based on the fold deformation information, analyze the fold intensity and fold distribution pattern; Based on the wrinkle intensity and wrinkle distribution pattern, the first weight value of the wrinkle correction factor on the micromorphology of the grating lines is determined. Based on bubble deformation information, analyze bubble strength and bubble distribution patterns; Based on the bubble intensity and bubble distribution pattern, determine the second weight value of the bubble correction factor on the micromorphology of the grating lines; Based on the tensile deformation information, analyze the tensile strength and tensile distribution pattern; Based on tensile strength and tensile distribution pattern, the third weight value of the influence of tensile correction factor on the micromorphology of grating lines is determined. The comprehensive correction factor is obtained by weighting and fusing the wrinkle correction factor, the first weight value, the bubble correction factor, the second weight value, the stretch correction factor, and the third weight value.

[0088] In some embodiments, the degree to which different types of deformation (such as wrinkles, bubbles, and stretching) affect the micromorphology of the grating lines can vary significantly. Simply performing a fusion process may not accurately reflect the contribution of various deformations to the final correction result, thus affecting the accuracy and effectiveness of the correction.

[0089] Therefore, we can first analyze the wrinkle intensity and distribution pattern based on the wrinkle deformation information. Wrinkle intensity refers to the depth, height, or degree of influence of wrinkles on the microstructure of the grating lines, while wrinkle distribution pattern refers to the position, density, and arrangement of wrinkles on the surface of the cup. For example, image processing algorithms can be used to analyze three-dimensional topography data and identify the characteristic parameters of wrinkled regions. Based on the wrinkle intensity and distribution pattern, we can determine the first weight value of the wrinkle correction factor on the microstructure of the grating lines. This aims to quantify the importance or contribution of wrinkle deformation in overall deformation correction. For example, when the wrinkle intensity is high or the distribution is concentrated, the corresponding first weight value can be set to a larger value.

[0090] Then, based on the bubble deformation information, the bubble intensity and bubble distribution pattern are analyzed. Bubble intensity refers to the size, quantity, or degree of interference of bubbles with the micromorphology of the grating lines, while bubble distribution pattern refers to the position and aggregation of bubbles on the surface of the cup. For example, bubble characteristics can be determined by identifying local raised areas in the 3D topography data. Based on the bubble intensity and bubble distribution pattern, a second weight value for the influence of the bubble correction factor on the micromorphology of the grating lines is determined. This second weight value reflects the relative importance of bubble deformation in the overall correction.

[0091] Next, based on the tensile deformation information, the tensile strength and tensile distribution pattern are analyzed. Tensile strength refers to the local strain rate or degree of tensile deformation of a material, while the tensile distribution pattern refers to the range and direction of the tensile region. For example, the tensile region can be identified by analyzing changes in local geometric features on the surface of the cup. Based on the tensile strength and tensile distribution pattern, a third weighting value is determined for the influence of the tensile correction factor on the micromorphology of the grating lines. This third weighting value is used to quantify the contribution of tensile deformation in the overall correction.

[0092] Finally, a weighted fusion is performed based on the wrinkle correction factor, the first weight value, the bubble correction factor, the second weight value, the stretching correction factor, and the third weight value to obtain the comprehensive correction factor. Weighted fusion is a method of combining multiple factors according to their importance, such as using a weighted average or weighted summation. In this way, a comprehensive correction factor can be obtained, which can more comprehensively and accurately reflect the combined influence of different types of deformation on the micromorphology of the grating lines.

[0093] To illustrate this technical solution more clearly, a specific example is used below. Suppose that slight wrinkling deformation, moderate bubble deformation, and significant tensile deformation are detected in a localized area on the surface of the cup. First, based on the wrinkling deformation information, its intensity and distribution pattern are analyzed. For example, the wrinkle intensity is low and the distribution is sparse, thus determining the first weight value of the wrinkle correction factor on the micromorphology of the grating lines to be 0.2. Next, based on the bubble deformation information, its intensity and distribution pattern are analyzed. For example, the bubble intensity is moderate and the distribution is relatively concentrated, thus determining the second weight value of the bubble correction factor on the micromorphology of the grating lines to be 0.3. Subsequently, based on the tensile deformation information, its intensity and distribution pattern are analyzed. For example, the tensile strength is high and the distribution range is wide, thus determining the third weight value of the tensile correction factor on the micromorphology of the grating lines to be 0.5. Assume that the wrinkle correction factor has already been calculated as... The bubble correction factor is The stretching correction factor is Therefore, the comprehensive correction factor It can be calculated using a weighted fusion method, for example: This weighted fusion method ensures that the correction of the micro-geometric parameters of the grating lines can more accurately reflect the actual contribution of different deformation types to the final visual effect, thereby achieving more precise pattern correction.

[0094] Through the above technical solution, this embodiment fully considers the differences in the impact of different types of deformation on the micromorphology of grating lines. By introducing weight values, the comprehensive correction factor can more accurately reflect the actual deformation. Therefore, the accuracy and effectiveness of micro-geometric parameter correction can be significantly improved, ultimately enhancing the visual quality and consistency of the grating pattern on the 3D decorative cup, effectively reducing visual artifacts and distortions caused by deformation, and thus obtaining a more attractive product appearance.

[0095] The beneficial effects of implementing the embodiments of the present invention include: First, the geometric model and initial planar grating pattern of the 3D decorative cup are obtained. Then, feature analysis is performed on the geometric model to obtain the geometric feature information of the cup surface. The cup surface is divided into regions to obtain multiple local regions. Then, a set of deformation compensation strategies is established. Based on the regional geometric features of the local regions and the injection molding process parameters, a target compensation strategy is selected from the set of deformation compensation strategies. Finally, based on the target compensation strategy, the local pattern corresponding to the local region in the initial planar grating pattern is geometrically corrected to obtain a corrected pattern. Multiple corrected patterns are integrated to obtain a pre-compensated planar grating pattern for grating film fabrication. This allows for pre-compensation of the grating pattern by combining the features of each local region to realize the decorative cup design and improve the pre-compensation accuracy.

[0096] like Figure 2As shown, this embodiment of the invention also provides a 3D decorative cup design system incorporating planar grating patterns, comprising: The data acquisition module 701 is used to acquire the geometric model and initial planar grating pattern of the 3D decorative cup; The model feature analysis module 702 is used to perform feature analysis on the geometric model to obtain the geometric feature information of the cup surface; The region division module 703 is used to divide the surface of the cup into regions based on geometric feature information, thereby obtaining multiple local regions; The compensation strategy establishment module 704 is used to establish a set of deformation compensation strategies, which includes geometric feature compensation strategies, injection molding process parameter compensation strategies, and material non-uniform shrinkage compensation strategies. The target strategy selection module 705 is used to select a target compensation strategy from the set of deformation compensation strategies based on the local geometric features and injection molding process parameters of the local area. The pattern geometry correction module 706 is used to perform geometric correction on the local pattern corresponding to a local area in the initial planar grating pattern according to the target compensation strategy, so as to obtain the corrected pattern. The pre-compensation pattern integration module 707 is used to integrate multiple correction patterns to obtain a pre-compensation planar grating pattern, which is used for grating film fabrication.

[0097] The content of the above method embodiments is applicable to this system embodiment. The specific functions implemented in this system embodiment are the same as those in the above method embodiments, and the beneficial effects achieved are also the same as those achieved in the above method embodiments.

[0098] The embodiments described in this application are for the purpose of more clearly illustrating the technical solutions of the embodiments of this application, and do not constitute a limitation on the technical solutions provided by the embodiments of this application. As those skilled in the art will know, with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of this application are also applicable to similar technical problems.

Claims

1. A 3D decorative cup design method incorporating a planar raster pattern, characterized by, Includes the following steps: Obtain the geometric model and initial planar raster pattern of the 3D decorative cup; The geometric model is subjected to feature analysis to obtain the geometric feature information of the cup surface; Based on the geometric feature information, the surface of the cup is divided into regions to obtain multiple local regions; A set of deformation compensation strategies is established, which includes geometric feature compensation strategies, injection molding process parameter compensation strategies, and material non-uniform shrinkage compensation strategies. Based on the regional geometric features and injection molding process parameters of the local area, a target compensation strategy is selected from the set of deformation compensation strategies; According to the target compensation strategy, the local pattern corresponding to the local area in the initial planar grating pattern is geometrically corrected to obtain the corrected pattern. Multiple correction patterns are integrated to obtain a pre-compensated planar grating pattern, which is used for grating film fabrication.

2. The method according to claim 1, characterized in that, The step of geometrically correcting the local pattern corresponding to a local region in the initial planar grating pattern according to the target compensation strategy to obtain a corrected pattern includes: Obtain the injection molding material parameters for the 3D decorative cup; Based on the injection molding material parameters, the flow and cooling solidification process of the molten plastic is simulated, and the residual stress distribution inside the cup body after solidification is calculated. Based on the residual stress distribution, the surface of the cup is adaptively divided to obtain multiple micro-regions with uniform stress. The stress features are obtained by extracting features from the stress-uniform micro-region. Based on the stress characteristics, a target compensation command is generated, which is used to counteract the micro-torsion caused by stress. According to the target compensation instruction and the target compensation strategy, the local pattern corresponding to the local area in the initial planar grating pattern is geometrically corrected to obtain the corrected pattern.

3. The method according to claim 2, characterized in that, The step of generating a target compensation command based on the stress characteristics includes: Obtain actual local physical property data of the injection molding material in the stress-uniform micro-region, including material temperature, pressure, and cooling rate; Based on the actual local physical property data, the stress-strain conversion coefficient is determined; Based on the stress-strain conversion coefficient, an initial compensation command is generated; Based on the stress characteristics, the initial compensation command is randomly perturbed to generate multiple candidate compensation commands; The candidate compensation commands are simulated to correct the micromorphology of the grating lines, and the simulation results are obtained. Based on the simulation results, the micromorphological consistency of the grating lines is judged, and the judgment result is obtained. If the judgment result meets the consistency standard, then the initial compensation instruction is used as the target compensation instruction.

4. The method according to claim 3, characterized in that, The initial compensation command is randomly perturbed based on the stress characteristics to generate multiple candidate compensation commands, including: Based on the stress characteristics, determine the type and degree of micro-twist that occurs in the grating lines within the stress-uniform micro-region; Based on the micro-twist type, the degree of micro-twist, and the actual local physical property data, set the parameter space boundary for the random perturbation; Based on the parameter space boundary, multiple candidate compensation instructions are generated.

5. The method according to claim 3, characterized in that, The simulation of grating line micromorphology correction for the candidate compensation command, to obtain simulation results, includes: The microscopic geometric parameters of the grating lines and the local geometric features of the cup surface within the stress-uniform micro-region are obtained. Based on the microscopic geometric parameters and the local geometric features, a multi-angle virtual observation path is constructed, which is used to simulate the propagation path of light on the grating microstructure and the surface of the cup. Based on the multi-angle virtual observation path, the projection pattern of the grating lines on the surface of the cup is analyzed by parameters to obtain the moiré fringe intensity, moiré fringe spatial frequency, visual artifact intensity, and visual artifact spatial frequency. Calculate the moiré fringe suppression factor based on the moiré fringe intensity and the moiré fringe spatial frequency; Calculate the visual artifact suppression factor based on the visual artifact intensity and the visual artifact spatial frequency; The moiré fringe suppression factor is compared with the preset moiré fringe suppression threshold to obtain the first comparison result; The visual artifact suppression factor is compared with the preset visual artifact suppression threshold to obtain a second comparison result; The simulation results are generated based on the first comparison result and the second comparison result.

6. The method according to claim 3, characterized in that, The step of judging the micromorphological consistency of the grating lines based on the simulation results, and obtaining the judgment result, includes: The microscopic geometric parameters of the grating lines and the local geometric features of the cup surface within the stress-uniform micro-region are obtained. Based on the aforementioned microscopic geometric parameters and the human eye's stereoscopic perception sensitivity curve, the virtual stereoscopic disparity change is calculated. The virtual stereo disparity change is compared with a preset stereo coherence threshold to obtain a third comparison result; The diffraction efficiency is calculated based on the microscopic geometric parameters and the optical diffraction characteristics of the grating microstructure. The diffraction efficiency is compared with the preset sharpness threshold to obtain a fourth comparison result; Based on the local geometric features, calculate the projected deformation of the grating lines on the surface of the cup. The projection deformation is compared with the preset local distortion threshold of the grid line to obtain the fifth comparison result; Based on the third comparison result, the fourth comparison result, the fifth comparison result, and the simulation result, it is determined whether the grating lines meet the micromorphological consistency standard, and the determination result is obtained.

7. The method according to claim 6, characterized in that, After obtaining the microscopic geometric parameters of the grating lines within the stress-uniform micro-region, the method further includes: Multi-point laser scanning measurements were performed on the surface of the cup to obtain the three-dimensional morphology data of the grating film on the surface of the cup. Based on the three-dimensional topography data, target deformation information of local areas of the grating film is identified, including wrinkle deformation information, bubble deformation information and tensile deformation information. The microscopic geometric parameters are corrected based on the target deformation information.

8. The method according to claim 7, characterized in that, The step of correcting the microscopic geometric parameters based on the target deformation information includes: Based on the fold deformation information, determine the local curvature changes and material accumulation degree of the folded region; Calculate the wrinkle correction factor based on the local curvature change and the degree of material accumulation; Based on the bubble deformation information, determine the local bulge height and boundary gradient of the bubble region; Calculate the bubble correction factor based on the local bulge height and the boundary gradient; Based on the tensile deformation information, the local strain rate and tensile direction of the tensile region are determined; Calculate the tensile correction factor based on the local strain rate and the tensile direction; The wrinkle correction factor, the bubble correction factor, and the stretch correction factor are fused together to obtain a comprehensive correction factor. The microscopic geometric parameters are corrected according to the comprehensive correction factor.

9. The method according to claim 8, characterized in that, The process of fusing the wrinkle correction factor, the bubble correction factor, and the stretch correction factor to obtain a comprehensive correction factor includes: Based on the fold deformation information, analyze the fold intensity and fold distribution pattern; Based on the wrinkle intensity and the wrinkle distribution pattern, determine the first weight value of the influence of the wrinkle correction factor on the micromorphology of the grating lines; Based on the bubble deformation information, analyze the bubble strength and bubble distribution pattern; Based on the bubble intensity and the bubble distribution pattern, a second weight value for the influence of the bubble correction factor on the micromorphology of the grating lines is determined; Based on the tensile deformation information, analyze the tensile strength and tensile distribution pattern; Based on the tensile strength and the tensile distribution pattern, a third weight value for the influence of the tensile correction factor on the micromorphology of the grating lines is determined. The comprehensive correction factor is obtained by weighting and fusing the wrinkle correction factor, the first weight value, the bubble correction factor, the second weight value, the stretch correction factor, and the third weight value.

10. A 3D decorative cup design system incorporating planar lenticular patterns, characterized in that, include: The data acquisition module is used to acquire the geometric model and initial planar grating pattern of the 3D decorative cup; The model feature analysis module is used to perform feature analysis on the geometric model to obtain geometric feature information of the cup surface; The region division module is used to divide the surface of the cup into regions based on the geometric feature information, thereby obtaining multiple local regions; The compensation strategy establishment module is used to establish a set of deformation compensation strategies, which includes geometric feature compensation strategies, injection molding process parameter compensation strategies, and material non-uniform shrinkage compensation strategies. The target strategy selection module is used to select a target compensation strategy from the deformation compensation strategy set based on the regional geometric features of the local area and the injection molding process parameters. The pattern geometry correction module is used to perform geometric correction on the local pattern corresponding to a local area in the initial planar grating pattern according to the target compensation strategy, so as to obtain a corrected pattern. The pre-compensation pattern integration module is used to integrate multiple correction patterns to obtain a pre-compensation planar grating pattern, which is used for grating film fabrication.

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